Handsaw

ABSTRACT

A relatively economical and simply constructed handsaw is comprised of a one piece molded holder and a flexible saw blade firmly retained therein. The holder has a handle portion with a longitudinally extending passageway in which a portion of the blade is slidably seated, and a relatively rigid support portion extending from one end thereof and providing support for the blade at a point spaced from the handle portion. The external configuration of the handle portion is complex and is shaped to provide a secure and comfortable grip during use.

[limited States Patent m1 West [45; Sept. 4, r973 HANDSAW [75] Inventor:Robert F. West, West Simsbury,

Conn.

[73] Assignee: The Stanley Works, New Britain,

Conn.

[22] Filed: May 3, 1971 21 Appl. No.: 139,546

[52] 11.8. CI 145/108 R [51] Int. Cl. BZSg 1/10, B27b 21/02 [58] Fieldof Search 30/335; 145/31 R, 145/31 B, 35 R, 35 D, 35 E, 62, 63, 64, 108R, 108 A [56] References Cited UNITED STATES PATENTS 2,331,638 10/1943Taylor 145/31 R 2,920,668 l/l960 Leist 145/31 R 2,139,147 12/1938 Blum145/35 E 2,655,963 10/1953 Dell 145/29 R 3,447,580 6/1969 Keymer 145/108R FOREIGN PATENTS OR APPLlCATIONS 935,876 9/1963 England 145/31 RPrimary Examiner-Othell M. Simpson Assistant Examiner-Mark S. BicksAttorney-Peter L. Costas [5 7 ABSTRACT A relatively economical andsimply constructed handsaw is comprised of a one piece molded holder anda flexible saw blade firmly retained therein. The holder has a handleportion with a longitudinally extending passageway in which a portion ofthe blade is slidably seated, and a relatively rigid support portionextending from one end thereof and providing support for the blade at apoint spaced from the handle portion. The external configuration of thehandle portion is complex and is shaped to provide a secure andcomfortable grip during use.

8 Claims, 8 Drawing Figures HANDSAW BACKGROUND OF THE INVENTION Varioustypes of handsaws have been devised and are widely employed for cuttingapplications, and these saws may have different constructions dependingupon the intended application and the cutting blade to be used therein.For example, hacksaws customarily employ a frame to support the thinflexible blade at a point spaced forwardly of the handle. Cross-cut andrip saws generally rely upon a tapered blade of relatively great widthto provide the desired strength and resistance to excessive bending butonly secure that blade at the handle. There have been many efforts todevise simple and relatively low cost constructions for handsaws whichwould facilitate the interchangeability of blades and which wouldprovide means for simple engagement of such blades while permitting theuse of the tool for various cutting applications.

In making tools for the home market, there has been a growing trend tosimplified and more economical construction; unfortunately, this hasoften been at the expense of good gripping or handling characteristicsor at the expense of durability. Since the sawing action requires a goodgrip upon the tool, it is extremely desirable that any tool be soconfigured as to provide a comfortable and secure grip for the user.Moreover, if the number of component parts is reduced, it should not beat the expense of durability and proper support for the blade.

Accordingly, it is the primary object of the present invention toprovide a novel handsaw including an integrally formed, one piece holdermolded from a synthetic resinous material and affording a comfortableand secure grip during use.

It is also an object of the invention to provide a hand saw of theforegoing type in which the support portion of the holder is configuredto provide a relatively large clearance area over the portion of theblade extending thereacross, while at the same time providing firmsupport therefor.

Another object is to provide such a handsaw having clamping means on thesupport portion which is of simple design and yet highly effective.

Still another object of the invention is to provide such a handsawwherein the passageway through the handle portion is especiallyconfigured to permit facile insertion of the saw blade thereinto whileat the same time limiting twisting and other undesirable movement of theblade about its longitudinal axis within the holder.

A still further object of the invention is to provide such a handsawhaving the foregoing features and advantages, which in addition employsrelatively few and simple components, and which may be produced in arelatively facile and economical manner.

SUMMARY OF THE INVENTION longitudinal passageway, in which a portion ofthe saw blade is slidably seated, and a rigidsupport portion ofgenerally inverted U-shaped configuration. The support portion extendsfrom one end of the handle portion, and has its free end providingsupport for the blade at a point spaced from the handle portion. Thehandsaw also includes means on the free end of the support portiondisengageably clamping the blade in a fixed position within the handle.The handle portion is elongated, and it has a complex externalconfiguration providing longitudinally extending ribs along the upperand lower side margins thereof and recessed side surface portionstherebetween. The configuration of the handle portion affords a secureand comfortable grip on the handsaw during use.

In the preferred embodiments of the invention, the generally invertedU-shaped support portion of the handsaw has an elongated center armspaced above the plane of the upper surface of the handle portion, toprovide an elongated clearance area above the blade. Preferably, astepped surface is provided on one side of the leg of the supportportion that provides the free end thereof, and the leg has an apertureextending therethrough. The stepped surface is adjacent the free end andprovides a shoulder that extends in the direction of the longitudinalaxis of the holder and that is of a depth substantially equivalent tothe thickness of the blade. The clamping means may include a fastenerextending through the aperture in the leg and a clamping plate seated onthe surface thereof and on the blade. The fastener draws the clampingplate tightly against the blade, and the blade thereby against thesurface of the leg, to clamp the blade tightly therebetween. Mostdesirably, the stepped surface of the leg providing the free end has adouble-stepped configuration providing a second shoulder spaced inwardlyfrom the first shoulder. The clamping plate is seated on the stepprovoding the second shoulder, the latter being of a depth substantiallyequal to the thickness of the clamping plate to provide a substantiallyflush side surface. Advantageously, the clamping plate is internallythreaded and cooperates with an externally threaded bolt to provide afastener, and ideally the aperture is present adjacent the firstmentioned shoulder. In such a case, the fastener extends below theshoulder with the blade bearing against the shank thereof.

Generally, the blade of the handsaw will be of substantially uniformwidth along its entire length and the passageway to the handle portionwill be dimensioned and configured to enable facile insertion andsliding movement of the blade thereinto. To restrict sidewise androtational movement of the blade within the passageway, the passagewaybeneficially has a portion of reduced cross-sectional area snuglyseating the blade. In preferred embodiments, the reduced portion of thepassageway extends inwardly from the one" end of the handle portion andthe passageway has a portion of greater cross-sectional area extendinginwardly from the opposite end thereof. The passageway of suchembodiments is dimensioned and configured to provide a trans-sectionalportion blending the reduced and greater cross-sectional area portionsand providing guide surfaces to facilitate insertion of the blade intothe passageway from the opposite end of the handle portion. Mostdesirably, the reduced cross-sectional area portion of the passagewayincludes generally U- shaped channels snugly seating the upper and loweredges of the blade, and the greater cross-sectional area portion thereofis of generally octagonal configuration.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of ahandsaw enbodying the present invention;

FIG. 2 is a side elevational view of the handsaw of FIG. 1 drawn to aslightly diminished scale and showing, in phantom line, the blade in anextended position;

FIG. 3 is a front end elevational view of the handsaw drawn to aslightly enlarged scale from that of FIG. 1;

FIG. 4 is a fragmentary exploded perspective view of the front end ofthe support portion of the holder and a portion of the blade that issupported thereby;

FIG. 5 is a fragmentary side elevational view of the front end of theassembled handsaw, with nut plate omitted for clarity of illustration;

FIG. 6 is a sectional view of the handsaw along line 6 6 of FIG. 2 anddrawn to an enlarged scale.

FIG. 7 is a sectional view of the handsaw along line 7 7 of FIG. 2 anddrawn to the same scale as FIG. 6; and

FIG. 8 is a perspective view of a section along line 6 6 of FIG. 2,drawn to a still further enlarged scale and with the blade removed toillustrate the configuration of the passageway through the holderthereat.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENT Turning now in detailto the appended drawing, therein illustrated is a handsaw embodying thepresent invention and including a one-piece holder, generally designatedby the numeral 10, which is molded from a synthetic resinous material.Mounted within the holder 10 is a hacksaw blade, generally designated bythe numeral 12, which is of conventional thin, flexible construction andhas a width dimension a" that is uniform along its entire length.

The elongated handle portion 14 of the holder 10 has a complex externalconfiguration providing longitudinally extending rib elements 16 alongthe lower side margins thereof, and recessed side surface portions 18that diverge upwardly and blend to an enlarged upper surface portion 20providing rib elements 21 thereat. This configuration of the handleportion 14 renders the saw comfortable to hold and enables securegripping thereof in the operative position; as will be noted, the handleportion 14 also has a complex curvilinear external configuration alongits longitudinal axis, which further contributes to the comfort andsecurity of the grip thereon. The eleptical apertures 22 that arecentrally located within the surface portions 18 are caused by the useof stabilizing mold elements, and serve no necessary function in thetool herein described.

The holder 10 also includes a generally inverted U- shaped supportportion, generally designated by the numeral 24, which consists of anelongated, generally rectilinear rigid arm 26 which extends along anaxis generally parallel to the axis of the handle portion 14 and isoffset a short lateral distance therefrom. One end of the arm 26 isspaced upwardly from and is attached to the adjacent end of the handleportion 14 by a short connecting leg 28, which blends into the contourof the handle portion 14. The leg 30 depending from the opposite end ofthe arm 26 to provide the free end of the support portion 24 affordsoverlying support for the blade 12 at a point spaced forwardly ofthe'handle portion 14 and has means therein for securing the blade, aswill be described hereinafter. The leg 28, the arm 26 and the leg 30cooperatively define an elongated, generally U-shaped clearance area 32extenxing above the portion of the blade 12 that projects from thepassageway of the handle portion 14.

As can best be seen in FIG. 4, one side surface of the leg 30 has adouble-stepped configuration provided by a first inside surface 40extending upwardly from the free edge of the leg 30 to the shoulder 41which extends in the direction of the longitudinal axis of the holder 10and is of a depth substantially equal to the thickness of the blade 12.The double-stepped configuration also includes a second, shallower sidesurface 42 that extends from the first shoulder 41 to an angularlydisposed shoulder 44, which rises to the plane of that side surface ofthe body of the leg 30. Centered on the shoulder 41, the leg 30 of thesupport portion 24 has a centrally located aperture 34 passingtherethrough, in which is received the threaded shank 36 of the slottedthumbscrew 38. As will be apparent from FIGS. 3 and 5, the upper edge ofthe blade 12 bears upon the shank 36 of the thumbscrew 38.

The blade 12 is secured on the step 40 defined by the shoulder 41 by thenut plate 46 which seats the step 42 of the leg 30. The nut plate 46 hasan angular edge which mates with the angular shoulder 44 of the leg 30.Tightening of the thumbscrew 38 creates a slight tuming movement uponthe nut plate 46, and produces a very tight and effective grip of thelower edge of the nut plate 46 upon the side surface of the saw blade 12to clamp it firmly against the step 40.

Turning now in detail to FIGS. 6 8, therein is best illustrated theexternal configuration of the handle portion 14 and the configuration ofthe passageway defined therethrough. The cross sectional configurationat the forward section of the passageway shown in FIG. 6 is defined bynarrow top and bottom U-shaped channels 48 defining a recess greaterthan the width of the blade 12, and a relatively wide center portiondefined by side surfaces which are spaced apart a distance considerablygreater than the thickness of the blade 12. Right anglular shoulders 52extend from the side surfaces 50 to the channels 52. As can beappreciated, the blade 12 snugly seats on the channels 52 to restrictmovement thereof about its longitudinal axis within the handle portion14 either in a sidewise or in a twisting manner.

The rearward portion of the passageway that is depicted in FIG. 7 isgenerally octagonal in configuration and includes side surfaces 50 andtop and bottom surfaces 48 that correspond to the bottom surfaces of thechannels 48 seen in FIG. 6. However, the crosssectional configuration ofthe relatively unrestricted portion of the passageway shown in FIG. 7omits the inwardly disposed right angular shoulders 5 to define thechannels 48 and instead has sloping surfaces 54. Beveled surfaces 56(shown in FIG. 8) provide a gradual transition between the shoulders 52and the sloping surfaces 54 and afford efi'ective guides to facilitateinsertion of the blade 12 from the rear of the handle portion 14.

As will be appreciated by those skilled in the art, the complexconfiguration of the passageway pennits it to be formed using a moldelement that consists of a relatively heavy base (of hexagonalcross-section) on which is supported a more delicate element having aconfiguration producing the compound rectangular shapes and the rightangle shoulders 54 present in the restricted portion of the passageway.The use of such a mold element greatly facilitates the production of theholders herein employed and of the desirably configured passagewaytherethrough.

The holder may be molded of any of numerous different types of syntheticthermosetting and thermoplastic resins. Exemplary polymers include thepolyolefins, such as polyethylene and polypropylene; the vinyl andvinylidene resins, such as polystyrene, polyvinyl chloride, impactpolystryrene and the ABS-types of graft copolymers; filled polymers,such as the fiberglass reinforced polyesters; the long-chain syntheticpolyamides, and many others.

The dimensions and external configuration of the holder will be chosenfor optimum strength, gripping comfort and security, consistent withappropriateness for the particular type and size of saw blade employed.Although hacksaw blades, with which the present tool is particularlywell adapted for use, may vary in length, a -inch long blade is typicaland is particularly convenient in providing a variety of adjustedpositions for different purposes. Thus, the cutting blade may be used ata point forwardly of the arm 30 as well as rearwardly thereof.

The particular means by which the blade is clamped may also varyconsiderably from that illustrated although that embodiment offers aparticularly effective means of tightly securing the blade in a quickand convenient manner.

Thus, it can be seen that the present invention provides a novel handsawincluding an integrally formed,

one piece holder molded from a synthetic resinous material and affordinga comfortable and secure grip during use. In the handsaw, the supportportion of the holder is configured to provide a relatively largeclearance area over the portion of the blade that extends thereacross,while also providing wholly adequate support therefor, and the clampingmeans on the support portion is of simple and yet highlyeffective-design. The

' passageway through the handle portion may be specifically configuredto permit facile insertion of the saw blade thereinto, while at the sametime limiting twisting and other undesirable movement of the blade aboutits longitudinal axis within the holder. Moreover, the handsaw employsrelatively few and simple components and may be produced in a relativelyfacile and economical manner.

Having thus described the invention, 1 claim:

1. A handsaw comprising a relatively thin and flexible elongated sawblade of substantially uniform thickness along its entire length; amolded one piece holder for said blade integrally formed from asynthetic resinous material and comprising a handle portion having alongitudinal passageway in which a portion of said blade is slidablyseated and a rigid support portion of generally inverted U-shapedconfiguration extending from one end of said handle portion andproviding a pair of depending legs and an elongated center arm with theleg at its free end providing support for said blade at a point spacedfrom said handle portion, said elongated center arm being spaced abovesaid saw blade to provide an elongated clearance area above said blade;and means on said leg at said free end of said support portiondisengageably clamping said blade in a fixed position within saidholder, said handle portion being elongated with a complex externalconfiguration providing longitudinally extending ribs along the upperand lower side margins and recessed side surface portions therebetween,said external configuration facilitating secure and comfortable grippingof said handsaw, said passageway through said handle portion beingdimensioned and configured to enable facile insertion and slidingmovement of said blade therethrough and said passageway having anelongated portion of reduced cross sectional area snugly seating saidblade to restrict horizontal vertical and rotational movement of saidblade in said passageway.

2. The handsaw of claim 1 wherein said elongated center arm is spacedabove the plane of the upper surface of said handle portion.

3. The handsaw of claim 2 wherein said leg of said support portionproviding said free end has a stepped surface on one side thereofadjacent said free end providing a shoulder extending in the directionof the longitudinal axis of said holder and of a depth substantiallyequivalent to the thickness of said blade, said leg having an apertureextending therethrough; and wherein said clamping means includes afastener extending through said aperture in said leg and a clampingplate seated on the surface of said leg and of said blade, said fastenerdrawing said clamping plate tightly against said blade and said bladethereby against the surface of said leg to clamp said blade tightlytherebetween.

4. The handsaw of claim 3 wherein the stepped surface of said legproviding said free end has a doublestepped configuration providing asecond shoulder spaced inwardly from said first shoulder, said clampingplate being seated on the step providing said second shoulder, saidsecond shoulder being of a depth substantially equal to the thickness ofsaid clamping plate to provide a substantially flush side surface.

5. The handsaw of claim 3 wherein said clamping plate is internallythreaded and cooperates with an externally threaded bolt to provide saidfastener.

6. The handsaw of claim 3 wherein said aperture is adjacent said firstmentioned shoulder and said fastener extends below said shoulder, saidblade bearing against the shank of said fastener.

7. The handsaw of claim 1 wherein said reduced portion of saidpassageway extends inwardly from said one end of said handle portion,and wherein said passageway has a portion of greater cross-sectionalarea extending inwardly from the opposite end of said handle portion,said passageway being configured and dimensioned to provide atransectional portion blending said reduced and greater cross-sectionalarea portions thereof and providing guide surfaces to facilitateinsertion of said blade into said passageway from said opposite end ofsaid handle portion.

ally octagonal configuration.

0 t; t W t Patent No. 3, 6, Dated Sept m r 1973 Inventofls) I 'Rfibolc't:Fu West It is certified that error appears in the above-identifiedpatent and that said Letters Patent are hereby corrected as shown below:

Column 6, Line 31, cancel "3" and insert "9", Column 6, Line 39, cancel"3" and insert 9 Column 6, Line 42', cancel "3" and insert "9"a Add thefollowing claim:

9. A handsaw comprising a relatively thin and flexible elongated sawblade of substantially uniform thickness along its entire length; andintegrally formed one piece holder for said blade comprising a handleportion having a longitudinal passageway in which a portion of saidblade is slidably seated and a rigid support portion of generallyinverted U-shaped configuration extending from one end of said handleportion and providing a pair of depending legs and an elongated centerarm with the leg at its free end providing support for said blade at apoint spaced from said handle portion, said elongated center arm beingspaced above said saw blade to provide an elongated clearance area abovesaid blade; and means on said leg at said free end of said supportportion disengageably clamping said blade in a fixedposition within saidholder, said handle portion being elongated with an externalconfiguration facilitating secure and comfortable gripping of saidhandsaw, said passageway through said handle portion being dimensionedand configured to enable facile insertion and sliding movement of saidblade therethrough and seating said blade to re strict sidewise androtational movement of said blade in said passageway, said elongatedcenter arm being spaced above the plane of the upper portion of saidhandle portion, said leg of said support portion providing said free endhaving a step surface on one side thereof adjacent said free endproviding a shoulder extending in the direction of the longitudinal axisof said holder and of a depth substantially equivalent to the thicknessof said blade,

F ORM 5 0-1050 (10-69) USCOMM-DC 60376-P69 U45. GOVERNMENT PRlNTlNGOFFICE: 1969 O366-334 I a Patent No. 3,756,298 Page 2 said leg having anaperture extending therethrough, said clamping means including afastener extending through said aperture in said leg and a clampingplate seated on the surface 0F said leg of said blade, said fastenerdrawing said clamping plate tightly against saidblade and said bladethereby against the surface of said leg to clamp said blade tightlytherebetween.

Signed and sealed this" 5th day of November 197 (SEAL) Attest:

McCOY M. GIBSON JR. C. MARSHALL DANN Attesting Officer Comissioner ofPatents

1. A handsaw comprising a relatively thin and flexible elongated sawblade of substantially uniform thickness along its entire length; amolded one piece holder for said blade integrally formed from asynthetic resinous material and comprising a handle portion having alongitudinal passageway in which a portion of said blade is slidablyseated and a rigid support portion of generally inverted U-shapedconfiguration extending from one end of said handle portion andproviding a pair of depending legs and an elongated center arm with theleg at its free end providing support for said blade at a point spacedfrom said handle portion, said elongated center arm being spaced abovesaid saw blade to provide an elongated clearance area above said blade;and means on said leg at said free end of said support portiondisengageably clamping said blade in a fixed position within saidholder, said handle portion being elongated with a complex externalconfiguration providing longitudinally extending ribs along the upperand lower side margins and recessed side surface portions therebetween,said external configuration facilitating secure and comfortable grippingof said handsaw, said passageway through said handle portion beingdimensioned and configured to enable facile insertion and slidingmovement of said blade therethrough and said passageway having anelongated portion of reduced cross sectional area snugly seating saidblade to restrict horizontal vertical and rotational movement of saidblade in said passageway.
 2. The handsaw of claim 1 wherein saidelongated center arm is spaced above the plane of the upper surface ofsaid handle portion.
 3. The handsaw of claim 2 wherein said leg of saidsupport portion providing said free end has a stepped surface on oneside thereof adjacent said free end providing a shoulder extending inthe direction of the longitudinal axis of said holder and of a depthsubstantially equivalent to the thickness of said blade, said leg havingan aperture extending therethrough; and wherein said clamping meansincludes a fastener extending through said aperture in said leg and aclamping plate seated on the surface of said leg and of said blade, saidfastener drawing said clamping plate tightly against said blade and saidblade thereby against the surface of said leg to clamp said bladetightly therebetween.
 4. The handsaw of claim 3 wherein the steppedsurface of said leg providing said free end has a double-steppedconfiguration providing a second shoulder spaced inwardly from saidfirst shoulder, said clamping plate being seated on the step providingsaid second shoulder, said second shoulder being of a depthsubstantially equal to the thickness of said clamping plate to provide asubstantially flush side surface.
 5. The handsaw of claim 3 wherein saidclamping plate is internally threaded and cooperates with an externallythReaded bolt to provide said fastener.
 6. The handsaw of claim 3wherein said aperture is adjacent said first mentioned shoulder and saidfastener extends below said shoulder, said blade bearing against theshank of said fastener.
 7. The handsaw of claim 1 wherein said reducedportion of said passageway extends inwardly from said one end of saidhandle portion, and wherein said passageway has a portion of greatercross-sectional area extending inwardly from the opposite end of saidhandle portion, said passageway being configured and dimensioned toprovide a transectional portion blending said reduced and greatercross-sectional area portions thereof and providing guide surfaces tofacilitate insertion of said blade into said passageway from saidopposite end of said handle portion.
 8. The handsaw of claim 7 whereinsaid reduced cross-sectional area portion of said passageway includesgenerally U-shaped channels snugly seating the upper and lower edges ofsaid blade, and wherein said greater cross-sectional area portionthereof is of generally octagonal configuration.